Hydrogen producing unit

ABSTRACT

An electrolyte electrolyzer adapted to create hydrogen and oxygen from electrolyte fluid at or near atmospheric pressure. The electrolyzer is comprised in a preferred form of a plurality of cells which collectively create oxygen and hydrogen chambers separated by an ion permeable membrane. The electrolyzer is further defined by a passive electrode that is electrically interposed between a charged anode and cathode. The chambers defined by the cells are in communication with oxygen and hydrogen supply lines to transfer the hydrogen gas from the unit.

RELATED APPLICATIONS

This application claims priority benefit of U.S. Provisional Ser. No.60/866,426, filed Nov. 19, 2006.

BACKGROUND OF THE INVENTION

Electrolysis has been utilized in many forms for separating water intomolecules of hydrogen and oxygen to create these elements in gaseousform. Many prior art methods of engaging in electrolysis are executed byway of pressurized water chambers with electrolyte solution. There arecertain electrolysis devices known as bipolar electrochemical cell typeelectrolysis devices, which apply a direct current voltage betweenoutermost electrodes that are in electronic communication withelectrolyte fluid. These devices employ a plurality of electrode plateswhich are positioned interposed between the outer electrodes, andeffectively act as bipolar electrode plates with one side operating asan anode and one side operating as a cathode.

SUMMARY OF THE DISCLOSURE

Disclosed below is an electrolyzer adapted to create gas. Theelectrolyzer is comprised of a plurality of cells that comprise a firstframe a portion and a second frame portion. In one form the first frameportion has a first longitudinal side and a recess area and a surfacedefining a lower open region. The second frame portion has a secondrecess area and a surface defining a second lower open region. A passiveelectrode is positioned adjacent to the first lower open region andpositioned adjacent to the first frame portion creating a first chamberregion.

The passive electrode is further in engagement with the second frameportion where the passive electrode is in engagement with the secondlower open region to partially define a second chamber region.

It should be noted that a charged cathode is position on one end of theunit and an opposing anode is positioned at the opposing end of the unitwith the passive electrodes electrically interposed therebetween.

A membrane is positioned on the second frame portion on an opposing sideof the second lower open region as to the location of the passiveelectrode.

The membrane is adapted to allow ions to pass there through but inhibitpassage of gaseous bubbles through the membrane. The membrane isoperatively configured to engage the first longitudinal side of thefirst frame portion for defining the first chamber region. The firstchamber region has an upper chamber portion in communication with afirst conduit for extracting an electrolyzed gas therefrom. The secondchamber region has an upper chamber portion in communication with asecond conduit for removal of the gas formed in the second chamberregion. The first and second chamber regions are not in communicationwith one another where gas formed in the first and second chamberregions are not in communication with one another.

In other forms the electrolyzer has the first and second conduits incommunication with a water replenishment and hydrogen removal system.The water replenishment and hydrogen removal system can comprise anoxygen chamber and a hydrogen chamber where hydrogen dispersion orificesare positioned in a lower portion of the hydrogen chamber beneath wherea fluid is to be contained therein. In one form the oxygen chamber andthe hydrogen chamber are in communication at lower passage positionedbeneath where the fluid is to be contained therein. A preferred fluid inthe chambers is an electrolyzer fluid that is in fluid communicationwith the plurality of cells.

With regard to the membrane of the cell, in a one form it is comprisedof a hydrophobic material. The hydrophic material has a tendency tomaintain the surface tension of the water surrounding the hydrogen andoxygen bubbles.

To define the electrolyzer in another fashion it comprises a housingadapted to house electrolyte fluid therein. The housing comprising aplurality of cells, and has a first chamber defined by a first ionpermeable membrane and a first electrode. Further a second chamber isdefined by the longitudinally rearward portion and a longitudinallyforward portion of a second ion permeable membrane, the second chamberbeing in communication with a hydrogen longitudinally extending passageand first chamber being in communication with an oxygen longitudinallyextending passage. The housing having a longitudinal, vertical andlateral axes a rearward longitudinal location and a forward longitudinallocation. A cathode is positioned in the rearward longitudinal locationand an anode positioned in the forward longitudinal location with aplurality of first and second chambers positioned therebetween, theplurality of first and second chambers being filled with an electrolytesolution whereby gas formed in the rearward and forward longitudinalportions of the electrode produces hydrogen which is passed through thehydrogen longitudinally extending passage and the forward portion of theelectrode produces oxygen which passes through the oxygen laterallyextending conduit and the first and second chambers are not in gaseouscommunication with one another.

In one form the electrolyzer comprises an electrolyte containmentchamber operatively configured to contain electrolyte solution therein.The electrolyte containment chamber comprises a plurality of electrodesand ion permeable membranes that are interposed amongst one other. Theplurality of electrodes and ion permeable membranes defining in part theoxygen and hydrogen chambers.

A cathode and an anode are positioned at first and second longitudinallocations within the electrolyte containment chamber. A firstelectrolyte supply channel in communication with a first lateral regionof the hydrogen and oxygen chambers and a second electrolyte supplychannel in communication with a second lateral region of the hydrogenand oxygen chambers, a pump operatively configured to bias theelectrolyte solution from the first electrolyte supply channel through alower portion of the hydrogen and oxygen chambers to the second lateralregion through the second electrolyte supply channel, whereas the ionpermeable membrane allows for electrical communication of theelectrolyte solution therethrough between the forward and rearwardadjacent electrodes which the ion permeable membrane is interposedbetween.

The disclosure recites herein a hydrogen gas producing unit adapted toproduce hydrogen from water and having a longitudinal, vertical andlateral axes. The hydrogen gas producing unit comprises a hydrogen gasproducing portion comprising a plurality of gas production cells, wherethe gas production cells comprising first and second chamber regionshaving lower and upper region portions. The first and second chamberregions are separated from one another for each cell in part by anelectrode and by an ion permeable membrane. The first and second chamberregions having a width dimension in the lateral axis greater than theheight dimension in the vertical axis direction.

A re-circulatory channel is provided and positioned in communicationwith the first and second chambers, the first chambers of the pluralityof cells having an upper portion in communication with a first passage,and the second chamber being in communication with a second passage.

A fluid replenishment system is provided and has a fluid compartmenthaving a fluid height sensor measuring the level of fluid therein, theswitch and the fluid compartment being in fluid communication with thefirst and second chambers of the plurality of cells, the gas exitingfrom the first chamber being hydrogen gas and being deposited through afluid trap and extracted through a gas extractor. A power control systemprovides direct current to the anode and cathode to be conducted betweenthe cathode and the anode.

The electrolyzer in one form can have a where a second conductor isinterposed between the anode and cathode where when the resistance isgreater through the plurality of cells, the second conductor is inelectrical communication with the either the anode and cathode soelectrical current only passes through a limited number of the pluralityof cells.

In one form the recirculatory passages are positioned beneath the firstand second chambers. The first and second frame portions can have alower first and second longitudinally extending conduit adapted to passelectrolyte fluid therethrough, where a surface defining an openingdefines the first and second electrolyte re-circulatory paths. In thisform the cross-sectional area of the electrolyte supply path can be lessthan 5% of the cross-sectional area of the hydrogen chamber in thelongitudinal direction. Each of the cells can have a surface thatcollectively creates a manifold structure for distributing electrolytefluid through each of the oxygen and hydrogen cells where the fluidtravels in a lateral direction.

Other attributes and variations of the hydrogen producing unit aredescribed herein.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an isometric view of the electrolyzer showing the rearwardportion, namely the power electronic section;

FIG. 2 shows another isometric view of the electrolyzer, in part showingthe hydrogen removal portion and water replenishment mechanism;

FIG. 3 shows the hydrogen producing portion of the electrolyzer;

FIG. 4 shows another isometric view of the hydrogen producing portion;

FIG. 5A shows a view taken along the longitudinal axis of the unit;

FIG. 5B shows the water filter of the unit as well as the lower coolinggrid for the electrolyzer solution;

FIG. 5C shows the cooling fan that is configured to bias air across thecooling grid;

FIG. 6 is taken at line 6-6 of FIG. 5A and shows the plurality ofhydrogen producing cells in a broken cross-section;

FIG. 7 shows a close up view of the end portion of the broken view ofthe plurality of cells;

FIG. 8 shows an exploded view of a cell structure which provides forhydrogen and oxygen production chambers;

FIG. 9 is a front view of itself;

FIG. 10 shows a front view of one of the components to comprise a cell;

FIG. 11 is taken along line 11-11 of FIG. 9 and shows a plurality ofcells in a cross-sectional view;

FIG. 12 is taken along line 12-12 of FIG. 9 illustrating the productionof hydrogen and oxygen in separate chambers;

FIG. 13 is taken along line 13-13 of FIG. 9 showing a top sectional viewlooking downward upon the chambers defining longitudinally extendedpassageways for removal of the oxygen and the hydrogen;

FIG. 14 shows a broken sectional view of a cell showing therecirculation path of the electrolyte fluid in the lower-right handportion;

FIG. 15 shows another broken view of an end region of a cell;

FIG. 16 shows a broken view of an end region of the plurality of cells

FIG. 17 schematically shows the number of cells and further shows thevoltage drop from the cathode to the anode therebelow;

FIG. 18 schematically shows the resistance and amperage in the verticaldirection along a cell, which is producing gaseous bubbles of hydrogenand oxygen;

FIG. 19 shows one form of the water replenishment and hydrogen removalsystem;

FIG. 20 is a rear view of the hydrogen removal and water replenishmentsystem;

FIG. 21 is an isometric view of the rearward portion of theelectrolyzer.

FIG. 22 shows a lateral view of one form of the power control system;

FIG. 23 shows a top view of the unit;

FIG. 24 shows a circuit schematic diagram of one form of a controlsystem for running the unit;

FIG. 25 shows another embodiment of an electrolyzer in an isometricview;

FIG. 25A shows a schematic second embodiment of the unit having aninterposed cathode/anode which can intercept and receive current toreduce the amount of resistance from one of the outer cathode/anodes foran alternative system for adjusting the amount of current flowingthrough the unit;

FIG. 26 shows a top view of the second embodiment;

FIG. 26A schematically shows a circuit diagram for recirculating theelectrolyte solution and replenishment of the same.

FIG. 27 shows a cross-sectional view taken along line 27-27 of FIG. 26showing the control system;

FIG. 28 shows an isometric view of the outer containment structure whichshows the path of the various cooling channels for cooling the operatingfluid of the unit which in one form is an electrolyte solution;

FIG. 29 is a cross-sectional view taken along line 29-29 of FIG. 26showing the circulation of the operating fluid through a portion of theelectrolyzer 420;

FIG. 30 is a sectional view taken along 30-30 of FIG. 26 showing an endplate and the various passages extending along the longitudinal axis ofthe unit which includes hydrogen and oxygen connection lines as well asan operating fluid manifold in the lower portion of the plate;

FIG. 31 is taken along line 31-31 of FIG. 26 showing and end plate:

FIG. 32 is taken along line 32-32 of FIG. 26 showing a front view of acell and illustrating the flow of the operating fluid therethrough inone form;

FIG. 33 shows a front view of a cell with the electrode which in oneform is a metallic electrode shown in the central portion of the cell;

FIG. 34 shows a rear view of a first section member of a cell where anelectrode is positioned thereon;

FIG. 35 shows the electrolyte positioned adjacent to the first sectionmember of a cell;

FIG. 36 shows a front view of a second section member with a membranewhich in one form is a hydrophobic membrane positioned in the rearwardportion of the cell;

FIG. 37 shows a rear view of the second section showing the membrane ina partial exploded manner;

FIG. 38 shows the membrane positioned adjacent to the rearward surfaceof the second section of a cell;

FIG. 39 is taken along line 39-39 of FIG. 33 showing a portion of theoxygen passageway;

FIG. 40 is taken along line 40-40 of FIG. 33 showing the central portionof the cell and the separating member;

FIG. 41 is a cross-sectional view taken at line 41-41 of FIG. 33 showinga portion of the oxygen subchamber;

FIG. 42 is taken along line 42-42 of FIG. 33 showing the hydrogenpassageway;

FIG. 43 is taken along 43-43 of FIG. 33 showing a sectional top view inpart with broken lines of the oxygen subchamber;

FIG. 44 shows a plurality of cell sections in a partially exploded view;

FIG. 44 shows four cell sections comprising (for example) four cells;

FIG. 46 shows a second cell section which in one form works inconjunction with a first cell section to form a stackable cell;

FIG. 47 is a sectional view taken along line 47-47 of FIG. 46 showingthe oxygen passageway;

FIG. 48 is a sectional view taken along line 48-48 of FIG. 46 showingthe central region of a cell;

FIG. 49 is a sectional view taken along line 149-49 of FIG. 46 showingthe hydrogen subchamber;

FIG. 50 is a sectional view taken along line 50-50 of FIG. 46 showingthe hydrogen passageway;

FIG. 51 is a sectional view taken along 51-51 of FIG. 46 showing a topsectional view of a plurality of cells, including first and second cellsection members.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

In FIG. 1 there is an isometric view of an electrolyzer 20. In general,the electrolyzer comprises a hydrogen/oxygen-producing portion 22, apower control system 24, and a water replenishment and hydrogen removalportion 26. To aid in the description of the electrolyzer 20, an axissystem is defined which is indicated at 10, where the axis 12 indicatesa longitudinal direction and the axis 14 generally indicates a lateraldirection. Further, the axis 16 indicates a vertical direction. Ofcourse the axis system 10 is not intended to limit the invention to anyspecific orientation, but rather is used to generally aid in thedescription of the various forms of the disclosed embodiment.

In general, the hydrogen producing portion 22 produces hydrogen by wayof electrolysis, and as described herein. The electrolysis process isexecuted by way of a serial electrolysis type arrangement with the firstand second electrodes having anode and cathode voltage differential anda plurality of intermediate cathodes. The incremental voltage differencedrop from the cathode to the anode is divided by the number ofelectrodes 70 (see FIG. 8) so the voltage drop between two adjacentelectrodes is sufficient (e.g. approximately 2 volts) to allowelectrolysis to occur.

As shown in FIG. 6, there is a partial sectional view of thehydrogen-producing portion taken along the brake line 4-4 of FIG. 5A. Ingeneral, the hydrogen producing portion 22 comprises an anode 30 and acathode 32 which are on opposing ends of the unit. FIGS. 6 and 7 showthe cross-sectional view of the plurality of cells 34 described furtherherein. In general, a cell is shown in an exploded view in FIG. 8 andcomprises a hydrogen producing unit which is interposed between theanodes and cathodes 30 and 32 as shown in FIG. 4. The electrolyzerportion has a width dimension which is greater than the height dimensionto facilitate the production of hydrogen at atmospheric or nearatmospheric pressures. Further, an electrolyte is recirculated throughthe recirculatory channels in the lower portion of the unit at 90 and 92(see FIG. 8), further described herein.

In FIG. 3, there is a view of the hydrogen producing portion 22. Betweenthe anode 32 and the cathode 30 is a cell section 40 which comprises aplurality of cells 60 described further herein (see FIG. 8). FIG. 3shows a partial cut away view of the unit where the plurality of cellsin the cell section 40 are stacked interposed between the anode 30 inthe cathode 32. FIG. 4 is a similar view to that of FIG. 3 except theupper portion of the water replenishment and hydrogen removal portion 26is shown.

Referring ahead now to FIG. 8, there is shown an exploded view of a cell60. In general, the cell 60 in one form is comprised of a first section62 and a second section 64. The first and second sections 62 and 64 areconnected together where a membrane 66 is attached in one form to thesecond section 64 by an attachment strip 72 which is described furtherherein. Further, the electrode 70 is positioned on the first section 62by the attachment strip 68 and is located adjacent to the second section64.

As shown in FIG. 9, the first section 62 is shown a frontal view. Ingeneral, the cells 60 comprise a central chamber region 80. The centralchamber region is divided into subchambers each one respectivelyproducing hydrogen having hydrogen and oxygen produce therein in anintermittent order described further herein. Each of these subchambersis separated by either the membrane 66 or the electrode 70 of FIG. 8. Itshould be noted that by removing these barriers, there is clear accessthrough the central chamber region 80 which as shown in FIGS. 9 and 10is comprised of in one form for section laterally across the span of thecell 60. It should be further noted that first and second electrolytesupply channels 86 and 88 are provided in the lower portion of the cell60. Each of the central chamber regions 80 is defined by a lower innerface 36, an upper inner face 28, and opposing lateral inner faces 38. Inone embodiment, each of the cells 60 also comprise a downward extensionhaving a lower edge 42. As seen in FIG. 11, the upper edge 44 of themembrane 66 and/or electrode 70 is attached to this downward extension.

The first and second electrolyte supply channels 86 and 88 extend thelongitudinal axis of the unit whereby the first and second loweropenings 90 and 92 define the first and second electrolyte supplychannels 86 and 88. Therefore, there is an unobstructed path through theplurality of cells where the openings 90 and 92 all are in alignmentalong the cell section 40 (see FIG. 3) to create a manifold typestructure where electrolyte passes through the first and secondpassageways 94 and 96 to circulate electrolyte there through the centralchamber region 80 (comprised of the oxygen and hydrogen subchambers 130and 132, as shown in FIG. 11). For greater clarity of the understandingof the manifold like structure comprised of the plurality of surfaces 90and 92 of the cells, reference is made to FIGS. 14 and 15 where it canbe seen how the surfaces 90 are in positional alignment with adjacentcomponents (i.e. the second section 64 and the surface 90′). As shown inFIG. 15 there is shown how the passages 110 provide fluid communicationto the oxygen and hydrogen sub-chambers 130 and 132. It should be notedthat it is desirable to keep the cross-sectional area of the surfacesdefined in the openings 90 and 92 to a minimum because it is desiredhave a majority of the electric current to pass through the electrode 70(see FIGS. 11 and 12) to produce hydrogen. Therefore, thecross-sectional area of the first and second electrolyte supply channels86 and 88 is much less than the cross-sectional area in the longitudinaldirection of the oxygen and hydrogen chambers in the central chamberregion 80, such as that shown in FIG. 9. For example, thecross-sectional area can be less than 5% of the electrolyte supplychannel than the central chamber region 80. In a more preferred form,the cross-sectional area can be less than 2% and even less than 1% ofthe area. FIG. 10 is a front view of the second section 64 of the cell60. As shown in this figure the openings 86′ and 88′ correspond inlocation to the openings 86 and 88 of FIG. 9 in one form, as shown inFIG. 12 the first section 62 is partially comprised of an extension 100.The extension 100 is a lip like member substantially the shape of thefront cross-sectional area of the surface 90 as shown FIG. 9. Near thepassage 110 as shown in FIG. 9 is a slight cut out of this extensionthat is the approximate width of the passage 110, thereby allowingcommunication to the inner sub-chambers 130 and 132 for circulation ofthe electrolyte fluid (see FIG. 15). The second section 64 has areceiving portion 102 as adapted to sealingly engage the extension 100.In a like manner, the first section has a receiving portion 104 adaptedto receive the extension such as that is shown at 106 of the secondsection 64 (see FIG. 12). Of course it should be noted that thesectional view in FIG. 12 is taken along the broken sectional line 12-12of FIG. 9 which extends along the passageway 110 to illustrate the fluidpassage for circulation of the electrolyte solution.

Referring back to FIG. 11, there will now be a more detailed discussionof the first and second sections 62 and 64. FIG. 11 is taken along thesection line 11-11 of FIG. 9 illustrating subchambers which are formedby way of stacking the plurality of cells 60. For example, the firstcell 60′ is formed by the first and second section 62 and 64 in theleft-hand portion of the array of cell in FIG. 11. The first section 62comprises an attachment strip 68 which in one form is a suitable way forattaching the electrode member 70 thereto. The membrane member 66 isattached in a similar manner with the attachment strip 72 where theelectrode and the membranes are positioned in an alternative mannerthroughout the assembly of the cells 60. The oxygen subchamber 130 isformed between the membrane 66 and the electrode 70. The hydrogensub-chamber 132 is positioned on the other side of the electrode 70 andis defined by the adjacent membrane 66 as described further herein, itshould be noted that the electrode 70 is a passive electrode where ititself is not specifically connected to an anode or a cathode but hasanode and cathode like portions on opposing sides thereof. When an anodeor cathode is positioned at the longitudinal ends on other side of thecell assembly, the current passing there through electrolytes other sideof the electrode to form to produce electrolysis.

As noted above, the first electrode supply channel 86 is formed by theplurality of stacked cells 60 and as seen in FIG. 14 the first andsecond plates 62 and 64 form the manifold channel 87. It should be notedthat the cross-sectional area of the first and second electrode supplychannel 86 and 88, as well as the passages 110 (see FIG. 9) are kept toa minimum cross-sectional area. As described in detail below, a functionof the hydrogen production is based upon the amount of current travelingthrough the electrodes 70. Now referring to FIG. 12, it can be seen howbubble members are formed on either side of the electrodes 70. Inparticular, referring to the electrode indicated at 70′ in FIG. 12, itcan be seen if the current passes from the right-hand portion to theleft-hand portion, where the anode 32 as shown in FIG. 3 and the cathode30 supply current through all of the cells 40. The hydrogen productionoccurs along the hydrogen producing surface 135, and the hydrogenbubbles rise vertically through the electrolyte solution which isflooded through the hydrogen sub-chamber 132. Now referring to theadjacent oxygen sub-chamber 130, it can be appreciated how the oxygenbubbles 136 form on the opposing side of the electrode 70′ on the oxygenproducing surface 134. As schematically shown in FIG. 12, in generalthere will be twice as much hydrogen gas 133 produced by volume ascompared to the oxygen gas 136.

Now referring ahead to FIG. 17, there is schematically shown a pluralityof cells comprised in the cell section 40 which are all placed betweenthe cathode 30 and anode 32 and 30. It should be noted that in a directcurrent application, the voltage drop throughout the cells isschematically shown in the lower portion of FIG. 17. Given anapproximate linear resistance with respect to the longitudinal directionamongst the cell section 40, the voltage drop will be substantiallylinear pursuant to the equation V=I×R where V=voltage in volts [V],I=current in ampheres [A], and R=resistance in ohms [Ω]). In general,having an approximate 2 volt drop between each of the cells provides adesirable factor of safety for having sufficient voltage differentiationamongst the adjacent cells to produce hydrogen. Of course, this factorcan be adjusted depending upon temperature, electrolyte, say for example15% in one range and up to say 25% in a broader range.

Therefore, having for example sixty cells with a voltage differential ofone hundred and twenty volts between the cathode 32 and the anode 30,the system achieves an approximate two-volt drop per cell. In otherwords, referring to FIG. 17, if the distance indicated at 152 representsthe distance between two adjacent electrodes and adjacent cells, thevoltage drop 154 would be, for example, approximately 2 volts. Ofcourse, the voltage drop line 156 is shown as linear in FIG. 17, andgiven the various changes of medium through the membranes where currentmust travel through the membrane and the electrode, there would beslight deviations in the slope of this line, but FIG. 17 presents thegeneral idea of the voltage differentiation created amongst theplurality of passive electrodes.

In general, the length of the cell is dictated by the amount of gasproduced in the current therethrough. The current is primarilyrestricted by the amount of a general outlet which is approximately 13amps and 120 V in North America which is converted to direct current forthe application. The upper gas separation chamber is generally about onefourth of the total height of the entire chamber region (see FIG. 10).There should be a certain fluid level sitting above the electrode foroperation. Further, gas is produced so a fluid level raises because thegas obviously occupies volume when in operation. In one form there isapproximately a half-inch buffer zone 150 (as shown in FIG. 15) in theupper portion to allow the gas outlet to escape to the hydrogen andoxygen collection lines 160 and 168 (see FIGS. 9 and 10). Of course, thedimension 150 as shown in FIG. 15 can be within various ratios withrespect to the overall size and dimension of the cells. For example, asshown in FIG. 10, the dimension 150 can be, for example, between onehalf and one fourth the dimension of the overall height of the cellindicated at 202 in the left-hand portion of FIG. 10.

By having an ambient pressure system (or substantially ambient), acertain ratio of dimensions for the unit is desirable. Looking in theleft-hand portion of the figure of the cross sectional view in FIG. 18,it should be noted that there is greater current in the lower portion ofthe chambers than in the upper portion. Using a basic equation V=I×R,present analysis indicates that the upper integral section has a greaterresistance of electrical flow due to the resistance of the bubbles thataccumulate therein. Since the voltage is fixed, the bubbles causegreater electrical resistance and therefore the current therefore shouldbe lower in this region. If the current is lower, the current is afunction of bubble production and the upper region 161 will produce lesshydrogen or oxygen per linear portion in the vertical direction.

Still referring to FIG. 18, there is shown a non-uniform amperage-typeflow with respect to the vertical direction through the electrolytesolution in the plurality of cells. The resistance line indicated at 190is generally greater in the upper portion because the hydrogen andoxygen gas bubbles 133 and 136 have a greater inherent resistance tolowering electrical current passing therethrough. Of course, given thatV=I×R, the corresponding amperage indicated at 192 will be lower thanthe top portion and a greater amount of amps flow in the bottom portion.However, the greater amount of resistance in the amps that do passtherethrough create I² losses.

It should be noted of course that each electrode has gas generated oneither side on hydrogen and oxygen, and if the chambers were angled, itwould reduce the volume in the other portion of the adjacent chamber.The electrode could be slanted where the hydrogen produces twice as muchgas as oxygen. For example, the unit could be slanted at, say, between2-12° of the broader range with all sub-ranges included therebetween forpurposes of allowing the gas to be extracted more readily from thehydrogen side of, for example, the surface 135 in FIG. 12. Therefore,the hydrogen sub-chamber 132 could have the electrode slanted awaytherefrom for an optimized type of effect of producing maximum hydrogen.It should further be noted that, in theory, there may be less surfacetension, and the angle may be helpful to have the bubbles raise right upand not be conducive to stick or otherwise adhere to the portion of theelectrode.

Now looking at the isometric view which is shown in a partial sectionalportion in FIGS. 3 and 8, given the external parameters of power whichis about 120 V, between 13 to 15 amps, and a safe operating range of 13amps, the preferred sweet spot for the thickness 200 (see FIG. 13)dimensional size of a cell has been found to be about ¼ of an inch, plusor minus 50% in the broader range, and likely 10% to 20% in morepreferred ranges. The height indicated at 202 (see FIG. 10) isapproximately 3.0 to 4.0 inches, which appears to have a desirablevertical height given the amount of gas production on either side asdescribed herein. The width 104 in one form is approximately 12 inchesminus approximately two ¼ inch segments on the ends and the three ⅛ inchsupport portions 81. Of course, this could vary by plus or minus 40% or20% in a more preferred variation. discussed further herein is a secondembodiment with reference to FIGS. 33-51 which shows a more preferredembodiment where the approximate width overall width dimension 680 (seeFIG. 36) is 6.5 inches (+/−20% in other preferred forms) and the otherdimensions are to scale as drafted in these drawings. Of course, theheight dimension could be lowered, and it could be wider at the samecurrent density, which in a preferred form is approximately 0.12 ampsper centimeter squared, but could be as low as 0.08 amps per centimetersquared. If the cell is much wider and shorter, there is an issue ofhaving a higher concentration of bubbles in the upper portion of thecell. However, the practical effects of structural integrity and havinga proper form factor for fitting it in various usable typesenvironments, the width dimension 104 should be reasonable, and 12inches is operational in one form. The dimensions specified above areone method of undertaking the general teachings of the invention claimedherein.

With the foregoing description in mind, there will now be a discussionof the membrane 66, which is permeable to be extended and allows ions topass therethrough. In other words, in an electrolyte solution, thepassage of the current is executed by way of an exchange of ions.Therefore, for electrical communication between the first and secondelectrodes, the membrane 66 should be ion-permeable. However, themembrane should not allow communication of gases from adjacent oxygenand hydrogen cell chambers. For example, as shown in FIG. 12, thehydrogen sub-chamber 132′ is separated from the oxygen sub-chamber 136′.In other words, the membrane 66′ prevents cross-contamination ofhydrogen and oxygen gas, which is an explosive mixture. Therefore, theporosity of the membrane should provide holes at least 2.88 Å, whichwould be about the smallest size to allow hydrogen ions to passtherethrough. However, holes from 1-2μ should be acceptable values. Itshould be noted that although hydrogen gas molecules (H2) are verysmall, when the bubbles 133 form within the hydrogen sub-chamber 132,there is a water surface tension around the formed bubble.

If the membrane is, for example, hydrophilic where it “likes” water (apolar molecule) and presumably is more of a polarized structure ormaterial, the membrane could have a tendency to break away the smallboomerang-shaped water molecules and destroy the surface tension.However, if it is more of an oil-like substrate where it is hydrophobic(i.e. lipophilic), the membrane will tend to “stay away” from the polarbonds creating the water molecule surface tension and leave it intact.

It should also be noted that present analysis indicates that smallestbubbles that are formed are approximately 100μ across. The range can befrom the smallest range to allow ion flow therethrough, which isapproximately the size of the ions minus any interfering forces oneither side to inhibit the flow and up to a size below the bubble sizewhich present analysis estimates to be approximately 100μ. Of course ina broad range, this could be between 0.1μ to 90μ, and in one form a 1.2μmembrane has been utilized, but a 10μ porousity appears to be a safeporosity size to inhibit cross-contamination with the reasonable factorof safety worked therein. Present analysis indicates that certainmembranes may have a certain type of fibrosity property to them wheresmall fibers extend therefrom which can be problematic by causing arupture of bubbles, compromising the surface tension therearound.Further, they could hold the bubbles without having to move verticallyto get out of the unit. Of course it is desirable for this flow of thegas so resistance is minimized and production is sustained. Therefore,other properties to the membrane should be relatively smooth orotherwise not inhibit bubble destruction or slow the vertical flowthrough the fluid.

Referring now to FIG. 13, there is shown a top sectional view takenalong line 13-13 of FIG. 9. This view illustrates the gas chambers whichare formed, where the hydrogen sub-chambers 132 all pass upwardly to thehydrogen collection line 160. The hydrogen collection line 160 is formedfrom the plurality of surfaces 162 of the first and second sections 62and 64. The oxygen sub-chambers 136 are in communication with the oxygencollection line 168 which is formed by the plurality of surfaces 170.Therefore, in a similar manner as the electrode supply channels 86 and88 (see FIGS. 9 and 10), the collection lines 160 and 168 are formed bythe stacking of the plurality of cells.

With the foregoing description in mind, there will now be a discussionof the hydrogen water replenishment and hydrogen removal portion 26 asshown in FIG. 2. As described in detail below, the system 26 disclosesone form of replenishing the expended water, thus forming oxygen andhydrogen and further replenishing the water so it mixes properly withthe electrolyte solution to form a conducting electrolyte. Further, thesystem 26 performs a back check system to prevent an explosion fromtraveling back into the unit 22, causing damage to the unit and possibleinjury.

Referring ahead now to FIGS. 19-21, there is shown in FIG. 19 a frontpartial sectional view of the water replenishment and hydrogen removalportion of 26.

On the left hand portion there is a hydrogen chamber 220, on the righthand portion there is an oxygen chamber 222. Within the oxygen chamber222, there is a float valve (fluid height sensor) 224 which is inelectrical communication with the relay 244′ (see FIG. 22). The purposeof the sensor 224 is to ensure that the unit 20 does not operate whenthere is no ignition in the area of use where it is used as an oven, andprevent amperage passing through the unit if the water level is too low.One of the functions of the chambers 222 is as a flame arrester wherethe water bufferance will not allow passages of flame into the mainhydrogen and oxygen producing unit 24. The whole front unit operates asa P-trap which is conventional in the plumbing arts. The unit could beused to fuel an oven such as that as shown in U.S. Ser. No. 11/747,732which is fully incorporated by reference.

On the right-hand portion in FIG. 19 there is a water input valvechamber 227 which is in fluid communication with the left and rightchambers. It is advantageous to have the chamber 227 isolated becausethe hydrogen dispersion orifices indicated at 230 as well as the oxygendispersion orifices 232, as described further herein, are somewhatisolated from this portion to properly gauge the water level in thehydrogen producing portion 22 (see FIG. 2). The chambers 220 and 222 arein fluid communication at a lower passage 234 just to maintain thehydrostatic pressure therein, which keeps them substantially level withrespect to one another.

The operation control chamber control 240 is in fluid communication withthe electrolyte fluid to gauge the actual amount of fluid throughout thewhole unit. Any of the valves contained therein will shut off the unitif the electrolyte level is too low. The operation valve assembly 242operates as follows. The float switch 244 adjusts the electrolyte level,which opens a valve to allow water to enter the system. The second floatswitch 246 actually controls the high electrolyte level, which isdescribed further below. The third switch indicated at 248 will shut offthe unit if the electrolyte level keeps rising and is too high withinthe unit. It should further noted that the float switches are somewhatadvantageous for tilt control, at least about the longitudinal axis ofthe unit whereby tilted excessively in either direction of the floatswill essentially gauge this height variation from the adjacent fluid andshut off the machine.

There will now be a reference to the second switch 246. When this switchis “triggered” when the water level is low, the control system drawsfluid from the right-hand hydrogen and oxygen chambers 220 and 222through the opening 250 which has a metering orifice to control the flowrate therethrough. Of course any type of flow rate manipulative devicecould be utilized. It should be noted that there is another fluidcircuit system which is in communication with the operation controlchamber 242. The pump re-circulates fluid through the cells for variousreasons, such as a cooling of the liquid (pumping the liquid throughsome sort of refrigeration unit), and filtering the water.

As shown in FIG. 24 the valve 228′, which in one form is a solenoidvalve, is controlled by the float 228 of FIG. 19 where when the waterlevel is low, this valve is opened and additional water is fed into thesystem by a siphon opening 229 in FIG. 4. As shown in FIG. 20, the inlet229 is in communication with the passageways 231 to the lower point 233and back up to the upper portion 235 and into each respective chambernear the ports 230 and 232.

Therefore, the valve 244′ as shown in FIG. 22 is in communication withthe outlet 250 in FIG. 19, therefore when the float valve 244 is in thelow position, the electrolyte solution contained within the chambers 220and 222 are withdrawn therefrom.

As shown in FIG. 26A, when the valve 244 opens water is siphoned fromchamber 220 where the action of the pump 352 draws water therefrom andcirculates the water through the hydrogen producing portion 22 andthrough the heat exchanger/cooling grid 353 and the filter 355schematically show in FIG. 26A (shown in detail in FIGS. 5C and 5B).

Referring back to FIG. 19, the hydrogen gas is extracted through theoutput line 256, and the oxygen gas is extracted to the output line 258.As shown in FIG. 20, there is a rear view of the system 26 where it canbe seen that the oxygen receiving opening 170 is in communication withthe oxygen collection line 168 such as that shown in FIG. 13. In a likemanner, the hydrogen receiving opening 172 is in communication with thehydrogen collection line 160, also shown in FIG. 13. The verticallyoriented slots 174 and 176 are submerged in the electrolyte fluid inoperation, and the lower passages 178 and 180 are in communication withthe hydrogen and oxygen dispersion orifices 230 and 232 respectively.

With regard to FIG. 1 above, there is a synergistic effect of utilizingthe hydrogen and oxygen exit ports with the back flame protectionabilities, and also with utilizing the support to supply the unit withthe fresh fluid. Of course, the electrolysis reaction consumes water andbreaks it into its components, oxygen and hydrogen gas, so it must beconstantly supplied with fresh water. It should also be noted that inone form, sponges contained within the chambers 220 and 222 have theeffect of condensing some of the water within the hydrogen and acting asa scrubber. Also, the bubbles cut down noise and intend to change thecharacteristics and diameter of the bubbles in a more desirable fashion.

There will now be a discussion of an alternative power control systemwith reference to FIG. 25A. In general, given the basic concept of Ohm'slaw, the electrical resistance is a function of the temperature of theunit. The resistance is initially higher, the voltage is presumablyconstant across from the anode and cathode, therefore the current islower (in general). However, if say for example, there is an additionalcathode or anode interposed between the outer and housing innercathodes. In summary, a short circuit is created halfway along theresistance pass through the plurality of cells. Therefore, theresistance is lower in the shorter electrical path along thelongitudinal direction because it is simply not as long. The resistancebeing lower means the amps are the greater, which means a greaterproduction of hydrogen since the production of hydrogen is a function ofthe current. Now, after the unit heats up, the resistance will graduallydecrease thereby increasing the current. Of course, the heat andresistance relationship can have a recurring effect where if it heats uptoo much and the amps caused the heat since generally there is I² lossescreating heat. In this situation, the control unit will shut off or cutelectrical communication to the interposed anode/cathode (depending onthe configuration of the outer anode/cathode) and the outer extremeelectrode will be employed thereby increasing the resistance and hencecontrolling the current.

Therefore, with reference to FIG. 25A, there is shown a highly schematicversion of an alternative power control system, where an anode 230 ispositioned at one end of an array of cells 40′. The cathode 232 ispositioned at an opposing end in a longitudinal direction with theplurality of cells 60′ interposed their between. Therefore, as generallydescribed above, an anode (or alternatively a cathode to be placed inthe center portion) 230′ is positioned in closer proximity to the anode230, whereby a switch would electrically place the anode 230′ inelectrical communication, and the cell array indicated at 60′ would notbe invoked. In other words, the anode 230′ shortcuts the system to onlypass current through the cells indicated at 60′.

Referring to FIGS. 1 and 21, in general the power control board 24comprises an AC input region 320, a power supply portion 322, and a DCportion 324. Of course these portions can be present in a variety oflocations on the unit and are noted with the abstract labels togenerally classify the operation of the electronic controls. In generalthe AC input region 320 comprises a bracket strip 340 which in one formprovides an input for 120 V, 13 amp regular power input that isconventional in North America of course the unit could be arranged forother inputs such as 220V. There is a transformer 342 which supplieslow-voltage to the low-voltage power supply 350 described herein whichis a 12V unit to supply various solenoids and functionality such as thepump 352 and the cooling fan 354 (see FIGS. 5B and 5C). It should benoted that the low-voltage power supply 350 also energizes the relays228′ and 244′ as shown in FIG. 24. It should be further noted that inone form, the valves 228 and 244 operating the relays are 24V AC and ofcourse these valves are controlled by the relays by the floats asdescribed above. Of course any number of power controls could beutilized, but this is just one method of implementing the system.

There will now be a discussion of the first and second relays 360 and362. On the AC portion 320, the relay 360 is, in one form, implementedprior to the conversion of alternating current to direct current. Onereason for the position in the pre-direct current portion of the unit isbecause present analysis indicates there may be better longevity incontacts, and the current is simpler to handle when it is in analternating current state. The relay 360 is controlled by the relay 362which is described further herein, in particular with reference tocircuit schematic in FIG. 24. When the circuit relay 360 closes, therelay provides current power to the power supply 350 (see FIG. 1). Ofcourse this power supply is conventionally available to convert 120V ACto 120V DC. In one form, this power supply 350 has a current limitingfeature whereby the current will not exceed a certain amount given theresistance between the anode and cathode. Of course, with the embodimentas disclosed in FIG. 25A, a simpler type of power supply can be utilizedwhereby the control of the amperage is by way of a change in theresistance effectively by altering which anode is utilized.

As shown in FIG. 24, the discharge fuse 366 is utilized to preventvoltage build-up between the anode and cathode. In other words, when theunit ceases production, there is hydrogen and oxygen in the variouschambers. By way chemical potential energy, they can effectively operateas a fuel-cell producing electricity and inducing erosion and break downwithin the various metallic pieces in the passive conductors.

Still referring to FIG. 24, the ground wire is indicated at 370 in the120V AC current is received at 372. As further shown in FIG. 24, thereis a plurality of safety switches 374 where if they are all closed, theunit is in proper condition for operation. Therefore, as shown in FIG.24, when the main relay 360 is de-energized, the unit shuts off. Therelay 360 is de-energized when one of the switches 374 are open orotherwise hydrogen is not being produced in and the power supply 350(see FIG. 1) is not in operation.

Therefore, when the relay 360 is un-energized the schematic indicationsfor switches in are shown in a manner as in FIG. 24 where the contacts380 and 381 are closed, then the electrodes are in communication withthe resistor or fuse 361, whereby this inhibits the formation ofelectricity as described above.

However, when the unit is activated, the contact 380 is in electricalcommunication with the conductor 384 whereby the resistor/fuse 366 isnot in electrical communication, and the power supply 350 in anoperational state. Basically, direct current is fed to the electrodesschematically indicated at 383.

Now referring to the lower portion of the wiring schematic FIG. 24, thepump 391 is activated when the unit is turned on, and controlled by therelay 362 (see also in FIG. 22). The switch 402 as shown in FIG. 4 is atemperature switch. In a preferred form, this is the manual resetswitch, and when it is thrown it must be depressed again, presumably bya certified technician to inspect the machine to see why the temperatureincreased beyond acceptable levels. The blower switch 400 as shown inFIG. 4 and schematically shown in FIG. 24 is normally open because theunit is initially cold. However, when the unit heats up, the temperaturesensitive blower switch 400 closes, and the blower unit 355 is activated(see FIG. 5C) and is part of a heat exchanger to cool the electrolytefluid. Of course, a normal refrigeration type pump can be utilized tocool this fluid. In general the electrolyte fluid as it passes throughthe re-circulatory channel passes through the cooling grid 353 as shownin FIGS. 5A and 5B and the blower unit 355 as shown in FIG. 5C passesair therethrough to cool the electrolyte fluid.

With reference back to FIG. 24, 24V AC current is generated by thetransformer 342. The AC current passes through lines 410 and through thenormally closed switch and passes through the second relay 362. Theswitch member 412 provides electrical communication to the lineindicated 414. As described above, when the array of switches 374 areclosed when the unit is in proper functioning order and the relay 360 isactivated allowing current to pass to the electrodes indicated at 383.

Now referring to FIGS. 25-51, there is shown another embodiment. Forease of utilizing identifying numerals, where possible, similar numeraldesignations to previous components will be utilized and the numberswill be incremented by 400.

As shown in FIG. 25, there is an isometric view of the electrolyzer 420.The electrolyzer 420 in general comprises the hydrogen producing potion422 and an operating fluid cooling system 423. As described above and asshown in FIGS. 5 and 5C, there is shown a heat exchanger 353 which isone form of cooling the internal operating fluid which is water, and inone form an electrolyte solution described further herein. The operatingfluid cooling system 423 of the second embodiment as shown in FIGS.25-51 is integrated with the casing structure to show one form ofcooling the fluid while minimizing the footprint of the device. Itshould be noted that the isometric view in FIG. 25 would likely have afurther encasement positioned therearound in an operating model wherethe outer containment structure 433 would be, for example, quite warmwith the waste heat generated from the electrodes transferred to theoperating fluid. As shown in FIG. 26, there is a top view of thehydrogen producing portion 422, which is comprised of a plurality ofcells 434. The cells 434 are similar to the cells described above and asshown in FIG. 8-18; however, the modified cells shown herein have aslight advantage of the manifold channel 487 as shown in FIG. 32, whichis different from the manifold channel 87 as shown in FIG. 14 where thethroughput of the fluid is more electrically insular from the current inthe form as shown in the second embodiment. The details of the pluralityof cells 434, as shown in FIG. 26, will be discussed further herein. Asfurther shown in FIG. 26, there is a contact plate 634 which is incommunication with the active electrode 636. At the opposinglongitudinal region there is a contact plate 638 which is in electricalcommunication with the electrode 640. As discussed above, the electrodes636 and 640 can either be anode or cathode, depending on the flow of theelectrical current, to create either oxygen or hydrogen on either sideof the passive electrodes which are interposed between the electriccurrent. As further shown in FIG. 26, there is a schematic showingbiasing members, such as fans 642, which are configured to direct airthrough the open channel region 435 as shown in FIG. 27.

As shown in FIG. 26, the electrolyzer 420 further comprises a controlsystem 426 which operates to circulate the operating fluid, separate thegas from the liquid, and further provide a water sensing system toreplenish the fluid within the plurality of cells. Of course, thecontrol system 426 could be separated over a wider array of componentsand not necessarily consolidated on one end portion of the electrolyzer.Further, the control system need not have all of the functionalitydiscussed immediately above to be defined as a control system.

In general, the electrolyzer 420 as shown in FIG. 27 comprises an innercontainment structure 431 and an outer containment structure 433.Interposed between the containment structures is the open channel region435, which is configured to have air pass therethrough. As further shownin 27 and 29, there is a float member 690 which measures the fluid levelof the operating fluid contained within the containment structure 431.In general, the fluid level should be substantially level throughout thecontainment structure and throughout the plurality of cells. Therefore,the containment structure 431 generally operates as a type of bathtubfor the operating fluid and the various components flooded therein withthe operating fluid. An electric logic system can detect when the floatsensor 690 determines there is a low level of operating fluid, andadditional fluid can then be introduced by opening the valve 494, whichwould allow water (in a preferred form) to enter the system. If theelectrolyte is used, the electrolyte in most forms will not besacrificed and will remain within the inner containment structure 431.If electroplating is utilized for the various electrodes, then it ispossible to not utilize an electrolyte which would be further describedherein.

Therefore, there will first be an overall discussion of the fluidcooling system 423 with reference to FIGS. 27-32.

As shown in FIG. 28, there is an isometric view of the outer containmentstructure 433. It should be noted that there can further be an outercontainment structure as well which is schematically indicated by thehashed line 488 which could extend around the outer containmentstructure 433. In this form, this outer containment structure wouldprovide some insulation from the potential heat buildup of the operatingfluid passing through the outer containment structure as describedimmediately below. As shown in FIG. 25, the various output lines wouldextend in the outer portion of the containment structure, where forexample the water/electrolyte mixture fluid entry port 492 having thevalve 490 would for example extend through the outer containmentstructure as well as the hydrogen and oxygen exit lines. In general,this containment structure comprises an inner surface 437 which in oneform is a channel-like region. The inner surface is a sufficient widthand height to allow the outer surface of the inner containment structure431 to be positioned therein providing the open channel region 435 asshown in FIG. 27.

Referring now back to FIG. 28, it can be appreciated that there arefirst communication ports 441 and 443 which in one form are positionedon lateral regions of the outer containment structure on the first andsecond lateral members 457 and 459. Further, there is a secondcommunication port 445. In general, the communication ports 441 and 443in one form are discharge ports passing fluid from the control system426 to the cooling channels 461. Further, the second communication port445 is configured to pass the operating fluid back to the control systemand in one form directly to the fluid biasing member 489 (see FIG. 27)which will be described further herein. Referring now to FIG. 28, it canbe appreciated that the cooling channels 461 are comprised of an innerplate 463 and an outer plate 465. As shown in FIG. 27, the coolingchannel has a first section 461 a and a second section 461 b. The firstand second sections are separated by a separation member 467 which isbest shown in FIG. 28. There is further an additional separation member469.

FIG. 28 best shows the path of the fluid flow to and from the controlsystem 426. As shown in FIG. 27, the operating fluid exits the controlsystem 426, and in particular, the central chamber 491. The fluid passesinto the first section 461 a and extends longitudinally down thissection and takes a downward laterally inward path to the second section461V. The arrow 487 shows the general path of the fluid where the fluidtravels in the longitudinally forward direction back up through thesecond section 461B of the cooling channel and passes through the secondcommunication port 445. It should be noted that the inner surface 437 ofthe outer containment structure 433 is thermally conductive andtransfers heat from the inner and outer surface regions thereof.

Referring back to FIG. 26, it can be seen that the inner containmentstructure 431 is provided with an inner surface 491 which is slightlygreater than the outer surface of the plurality of cells 422. Ingeneral, the plurality of cells 422 are configured to have an operatingfluid, such as water and more specifically and water with an electrolytepass through a manifold channel 487. As described for further herein,the manifold channel is comprised of the plurality of stacked cellswhich each have a surface-correlating location to form an elongatechannel which is best shown in FIG. 26. To provide a preview of thediscussion to come, the manifold channel 487 in the right hand portionof FIG. 32 is in fluid communication with the fluid entry channel 590,which has an entry port 591 in the upper portion of the hydrogensub-chamber 132. The description of the fluid entry system and the gasremoval will be described further herein with a detailed description ofthe plurality of cells. At any rate, the operative fluid is configuredto come from the control system 426 as shown in FIG. 26, and travel downalong the manifold 487 where it exits from the back plate 511 asindicated by arrows 493. The fluid then travels along the inner surface491 of the inner containment structure 431 back to the control systemchamber 513. Thereafter, now referring to FIG. 27 which is taken alongline 27-27 of FIG. 26, the fluid exits the control system chamber 513and enters into the cooling channel 461 a in a manner as best shown anddescribed above with reference to FIG. 28.

Referring now to FIG. 29, it can be appreciated that the fluid reentersthe control system chamber 513 as shown by arrows 515 in FIG. 29. Thefluid biasing mechanism 489 in one form is a gear pump, but could be aplurality of types of pumps or mechanisms to reposition fluid.

After the fluid has passed through the gear pump, it extends radiallythrough the filter 519 in one form. The filter can be cylindrical andhave an inner chamber region 521 where the water is configured to passtherethrough as indicated by the arrows 523. In this form, the waterextends through the lower subline 525 and into the longitudinalextending passage 527 which is in communication with the manifoldchannel 487 as shown in FIG. 26. Therefore, it can be appreciated thatthe complete circuit of the fluid is configured to replenish the fluidlevel throughout the plurality of subchambers 532 and 530 describedherein, as well as recirculate the fluid through the fluid coolingsystem 423 to properly transfer heat therefrom so is the unit does notoverheat. It should be reiterated that in one form, the electrolyzer 420is at atmospheric pressure and is not a pressurized unit. Therefore, theoperating fluid, which in the preferred form is water or water with anelectrolyte mixture, should be maintained well below the boiling pointand preferred form at the prescribed range of 140-180 degrees F. In oneform the material comprises cells as plastic which can function up to180 degrees F.

Of course other forms of the unit could be pressurized to increase theboiling level of the operating fluid as well as decrease the bubble sizeof the hydrogen and oxygen, which is produced on either side of thepassive electrode 70 as shown in FIG. 12 and 470 as shown in FIG. 45 inthe second embodiment. In one form the members as shown in FIG. 12 couldbe vibrated so the prescribed desirable frequency to shake the bubblesloose from the electrode 70. In one form the resonant frequency of theelectrode can be determined and match a frequency generated to aresonant frequency or thereabouts to induce a vibration thereon tofurther stimulate the removal of the oxygen hydrogen bubbles from thesurface. For example, direct current passes in the unit between theanode and cathode but the frequency generator can be utilized toalternate the amplitude of the amperes traveling through.

As shown in FIG. 30, the first end plate 535 is shown, and the port 547is configured to communicate the manifold channel 487 (see FIG. 26) withthe control system chamber 513. It should be further noted that thehydrogen and oxygen collection lines 560 and 568 as shown in FIG. 30 arepositioned in the upper region of the plurality of cells 434 (see FIG.26), and FIG. 30 shows the first end plate 535 which providescommunication of the lines 568 and 560 to the oxygen and hydrogencollection chambers 571 and 573 as shown in FIG. 29. Further shown inFIG. 29 are the secondary passageways 569 and 561 which allow a certainamount of gas to pass therethrough and extend in the longitudinal firstdirection from the right to left-hand portions, as shown in FIG. 26, tothe collection chambers. As shown in FIG. 31, it can be seen that thesecond end plate 511, otherwise referred to as the backplate 511,provides openings for the electrolyte fluid to pass therethrough,indicated at 575 and 577. In one form the opening 575 in FIG. 31 couldbe reduced in this cross-sectional area to increase the fluid resistancepassing through to incite greater pressure within the manifold 47 asshown in FIG. 26 to induce to fluid flow into the hydrogen and oxygensubchambers through the first passage 590 as shown in FIG. 32.

Referring now to FIG. 33, there is shown a front view of a cell 460 ofthe second embodiment. The cell 460 is similar to the cells shown inFIGS. 9-11, described above with a few modifications. In general, eachof the cells are made in one form by matching pieces separated by anelectrode 470 and a membrane 466 (see FIG. 36).

With reference to FIG. 33, there will be a general discussion of thevarious sectional views looking at the first section member 462. Ingeneral, the first section members are mirror image of the secondsection member 464, although it should be reiterated that this need notbe the case. As shown in FIG. 39, it can be appreciative that the oxygenpassageway 568 is in communication with the second leg 609, which inturn is in communication with the oxygen subchamber. FIG. 40 is a centercross section showing the middle section separating member 606, which isprovided with the fluid passageway 602 in the lower portion, so thelateral regions of the subchamber 530 (see FIG. 32) can communicate withone another.

FIG. 41 shows a cross-section of the subchamber 530. It should be notedthat the spatial elements 610 are provided on both of the sectionmembers and aid in maintaining the separation between these adjacentmembers. FIG. 42 shows the cutout region 597 described below, andfurther illustrates the hydrogen passageway 560.

FIG. 43 shows a sectional view in the horizontal plane, perpendicular toa vertical axis, showing the first leg 605 of FIG. 33 and second leg 609of the oxygen gas trap 601. Further, on the right-hand side there isshown the fluid entry channel 590 a, which allows input from themanifold channel 487.

Referring now to FIGS. 33 and 36, it can be appreciated that these twomembers are front views of first and second sections 462 and 464.Referring to FIG. 33, the first section 462 in general has the electrode470 positioned in the rearward portion, and the front part of theelectrode 470 defines the oxygen subchamber 530 (see FIG. 12). Thesecond section 464 as shown in FIG. 36 would be positioned in the frontportion and the rearward portion of the member shown in FIG. 33 to formone have of the cell members of the plurality of cells 434 (as shown inFIG. 26). It should be noted that In the case of having water withoutelectrolyte the membrane 466 could be a proton exchange membrane thatcan be utilized to facilitate the electrical current passing through. ofcourse in this form the unit could further function as a fuel cell bybasically operating the various components of the hydrogen and oxygenseparation in reverse meaning hydrogen is supplied to the unit so as toinduce electric current which is common in the art of fuel cells.References such as U.S. Pat. No. 4,037,023 and U.S. Pat. No. 5,231,954are incorporated by reference.

FIG. 33 shows the surface defining the manifold channel, with theright-portion referred to as 478 a and the left-hand portion referred toas 478 b. The manifold channel 478 a is shown in FIG. 33 where the fluidentry channel 590 A. extends vertically and is configured to dispensethe operating fluid through the entry port 591 a. Therefore, as thefluid flows down the right-hand manifold channel 478 a, fluid isdirected upward through the fluid entry channel 590 to flood the oxygensubchamber 130.

As described in detail above, when a current is passed through theplurality of cells, gas is produced in a similar manner as shown in FIG.12. As shown in FIG. 33, as gas is produced, the oxygen passes throughthe oxygen gas trap past the first leg 605 downward past the lower point607 and then along the second leg 609 upwardly to the oxygen connectionline 568 where the oxygen gas extends longitudinally along the pluralityof cells 434 to the oxygen collection chamber 571 as shown in FIG. 26.

It should be noted that in FIG. 33 the lower subline 525 further allowsfor a certain amount of gas to pass therethrough. Experimentation hasfound that there is a fair amount of frothing that can occur when gasesmate, and the gas trap mechanisms 601 and 603 (as shown in FIG. 36) areconfigured to aid in containing the foaming within the oxygen andhydrogen subchambers.

Now referring to FIG. 36, it can be appreciated that the second section464 is shown which is substantially similar to the first section 462shown in FIG. 33. In fact, FIG. 33 and FIG. 36 are substantially mirrorimages of one another, with the exception of the separating material ofthe electrode 470 in FIG. 33 and the membrane 466.

Referring now to FIG. 36, it can be seen that in front portion of themembrane 466, there is defined a hydrogen subchamber 532 where thesecond section 464 could be placed behind the first section as shown inFIG. 33 and a closed chamber would form, with hydrogen bubbles formingon the rearward portion of the electrode 470 of FIG. 33 in a similarmanner as shown in FIG. 12.

Referring back to FIG. 36, in a similar manner, the manifold channel 478b is configured to deliver the operating fluid along the plurality ofcells, which have sufficient pressure to force the operating fluid upthe fluid entry channel 590 b and out the entry port 593 into thehydrogen subchamber 532. The membrane 466 is similar to the membrane 66described above, and in a preferred form the membrane is a hydrophobicmaterial which repels the surface tension around the bubbles of oxygenand hydrogen to allow them to pass vertically upwardly. In the case ofFIG. 36, the hydrogen bubbles blow upwardly (of course it should benoted that the creation of hydrogen and oxygen is contingent on thedirection of the current which in one form is a direct current) throughthe hydrogen gas trap 603. In general, hydrogen gas will pass down thefirst leg 613 past the low point 615 to the upper leg 617 and along thehydrogen connection line 560. The gas then travels in a longitudinallyforward direction to the hydrogen collection chamber 573 as shown inFIG. 26 and FIG. 29. FIG. 29 shows the cross-sectional view wherehydrogen and oxygen are dispersed from their respective chambers 573 and571 vertically outward towards the extraction ports 673 and 671 as shownin FIG. 25. Referring now to FIG. 32, it can be appreciated that theoperating fluid passes through the manifold 487, through the fluid entrychannel 590, and into the oxygen subchamber 530. In general, it isdesirable to have the fluid level at least the height of the member atthe upper portion indicated at 576. The fluid level is desirably belowthe upper perimeter region 576 of the electrode member within the oxygensubchamber 530 such that the current passes through the electrode memberto produce the hydrogen and the oxygen. As described above in the firstembodiment of the cell 60, the upper region of the subchamber indicatedat 578 is provided so that when the bubbles form, the net volume raiseswithin the subchambers. One issue introduced above is that of foaming.The gas traps 601 and 603 of FIGS. 33-36 help prevent the disbursementof the foam throughout the system. In other words, the fluid can have atendency to bubble excessively and create a foam-like air gascomposition which can flood the unit. As shown in FIG. 32, the passageof the gas indicated at arrow 579 downward to the lower region at 581tends to prevent the foam bubbles from propagating. A portion of the gascan then exit down the lower subline 525 and the remainder of the gas ischanneled upwardly through the oxygen passageway 568 as shown in FIG.32. Of course, a similar type of gas removal occurs on the opposing sideof the electrode 470 for escape of the hydrogen gas on the opposinglateral region through the gas trap 603 as shown in FIG. 36.

With the foregoing description in place, there will now be a discussionof the assembly of the second embodiment of the cells 460. As shown inFIG. 34, there is a first section 462 where in the rearward portion, theelectrode 470 is positioned thereagainst. FIG. 35 shows the electrodeplaced against the rearward surface of the first section 462. Nowreferring to FIG. 37, there is shown a second section 464 with amembrane member 466 placed upon the rearward surface of this section.FIG. 38 shows the membrane attached to the rearward surface of thesecond section 464. The membrane could be attached by way of anadhesive, or by simply being fitted thereagainst. Both the electrode 470and the membrane 466 can be attached in a similar manner.

In one form the electrode can have electrode plating positioned thereonthe electrode. In one form electroplating of the electrode(s) 470 canreduce the resistance barrier for electrons to pass because of thesurface effects. Effectively, the resistance drops and the lower voltageper-cell could be utilized between 1.65 V plus or minus 20% which couldbe 80-85% efficiency as present analysis indicates.

Now referring to FIG. 44, there is shown, in a partially exploded view,a plurality of first and second section members 462 and 464 whichcollectively will comprise a plurality of cells, and more particularly,two cells. The lower right plate is a plate having a membrane 466positioned thereon, and it can be appreciated that when the plurality ofsection members are positioned adjacent to one another as shown in FIG.45, the cells can be created to any prescribed length. As best shown inFIG. 45, the surface defining the cutout region 597 is provided whichhas the desirable effect of reducing the amount of material required tomake each section. Further, when the sections are plastic injectedmolded, this region provides a cutout portion so there is not a largepooling of hot plastic injected material requiring a greater cool timein this region.

Referring now to FIG. 46, there is shown a front view of a secondsection member 464 having the membrane 466 positioned thereon. Thisfront view in FIG. 46 is a front view of the collection of first andsecond members 462 and 464 as shown in FIG. 45. Because the secondsection 464 in this form is substantially a mirror image from left toright of the first section, the disclosure and description of thismaterial is relevant to the first section member 462. Of course, themembers need not be mere identical copies of one another.

Sequentially going from the sectional figures from FIG. 46, FIG. 47shows a sectional view of the oxygen passageway 568 and illustrates howthe oxygen subchamber 530 communicates with this passage. It can befurther seen how the lower subline 525 is in communication in the lowerregion of the plurality of cells.

Now referring to FIG. 48, there is shown a sectional view along thecenter portion of the cells where the thin sheets of electrode (which inone form is a metallic member 470) and the membrane 466 are interposedbetween the first and second sections 462 and 464. The separating member606 as shown in FIG. 46 helps maintain the volume of each of the oxygenand hydrogen subchambers and keep a separation of the membrane and theelectrode. Of course it can be appreciated that the upper portions ofthe oxygen subchambers 530 and the hydrogen subchambers 532 are shown inthe upper portion of FIG. 40 above the separator member 606.

Now referring to FIG. 50, there is shown the opposing view of FIG. 47where the hydrogen subchambers 532 are in communication with thehydrogen passageway 560. It can be appreciated that the oxygensubchamber 530 is not in communication with the hydrogen passageway 560.

FIG. 51 shows the sectional view taken at line 51-51 of FIG. 46illustrating the various subchambers as well as the cutouts 597 thisview illustrates the various passages of the p-trap mechanisms for thehydrogen and oxygen for purpose of removing the gas from theirrespective subchambers.

While the present the invention is illustrated by description of severalembodiments and while the illustrative embodiments are described indetail, it is not the intention of the applicants to restrict or in anyway limit the scope of the appended claims to such detail. Additionaladvantages and modifications within the scope of the appended claimswill readily appear to those sufficed in the art. The invention in itsbroader aspects is therefore not limited to the specific details,representative apparatus and methods, and illustrative examples shownand described. Accordingly, departures may be made from such detailswithout departing from the spirit or scope of applicants' generalconcept.

1. An electrolyzer adapted to create gas through electrolytic decomposition of a fluid, the electrolyzer comprising: a) a plurality of cells each cell comprising: i a first frame portion; ii a second frame portion; iii the first frame portion having a first longitudinal side, comprising a first recess area, and a downward vertically facing surface extending longitudinally only partway across the first recess area, the downward vertically facing surface defining a first lower open region within the first recess area; iv wherein the fluid fills the first lower open region during operation; v the second frame portion having a first longitudinal side adjacent the first longitudinal side of the first frame portion, and a second longitudinal side comprising a second recess area; vi the second recess area comprising a downward vertically facing surface extending longitudinally only partway across the second recess area, the downward vertically facing surface defining a second lower open region within the second recess area; vii wherein the fluid fills the second lower open region during operation; viii a passive electrode positioned adjacent to the first lower open region and positioned adjacent to the first frame portion creating a first interior surface of a first chamber region; ix the passive electrode further is in engagement with the second frame portion where the passive electrode is in engagement with the second lower open region to partially define a first longitudinal interior surface of a second chamber region; x a membrane positioned on the second frame portion on an opposing longitudinal side of the second lower open region relative to the location of the passive electrode; xi wherein the membrane allows ions to pass there through but inhibits passage of gaseous bubbles through the membrane; xii wherein the passive electrode comprises a thin sheet metallic member having a first longitudinal side forming the first interior surface of the first chamber region, and a second longitudinal side forming the first interior surface of the second chamber region; xiii the membrane defining a second interior surface of the first chamber region; xiv wherein the first recess area comprises a first chamber region within the first recess area, vertically above the upper edge of the membrane, the first chamber region having an upper chamber portion in communication with a first conduit for extracting an electrolyzed gas therefrom; and, xv wherein the second recess area comprises a second chamber region within the second recess area, vertically above the upper edge of the membrane, the second chamber region having an upper chamber portion in communication with a second conduit for removal of the gas formed in the second chamber region, and b) where the first and second chamber regions are not in fluid communication with one another vertically above the membrane.
 2. The electrolyzer as recited in claim 1 where the first and second conduits are in communication with a water replenishment and hydrogen removal system.
 3. The electrolyzer as recited in claim 2 where the water replenishment and hydrogen removal system comprises an oxygen chamber and a hydrogen chamber where hydrogen dispersion orifices are positioned in a lower portion of the hydrogen chamber beneath where a fluid is to be contained therein.
 4. The electrolyzer as recited in claim 3 where the oxygen chamber and the hydrogen chamber are in communication at lower passage positioned beneath where the fluid is to be contained therein.
 5. The electrolyzer as recited in claim 3 where the fluid to be contained therein is an electrolyzer fluid that is in fluid communication with the plurality of cells.
 6. The electrolyzer as recited in claim 1 where the membrane is comprised of a hydrophobic material.
 7. The electrolyzer is recited in claim 1 where a control system is configured to bias an operating fluid through a manifold channel of the plurality of cells; wherein the manifold channel is provided substantially below the first and the second lower open regions.
 8. The electrolyzer as recited in claim 7 where the manifold channel is provided with a fluid entry channel to provide communication to the first chamber of the plurality of cells where the fluid entry channel provides fluid communication between the manifold channel and the upper portion of the first chamber region above a fluid level of the chamber region so as to electrically insulate the electrical communication of the first chamber region to the manifold channel.
 9. The electrolyzer as recited in claim 8 where the fluid entry channel has an entry port positioned at the upper region of the chamber region and the first conduit for extracting the electrolyzed gas is positioned at a laterally opposite region of the first chamber with respect to the entry port of the fluid entry channel.
 10. An electrolyzer comprising a housing adapted to house electrolyte fluid therein, the housing having rearward and forward longitudinal locations, and comprising a plurality of cells, the electrolyzer comprising: a) a first chamber defined by a first ion permeable membrane and a first passive electrode; b) a second chamber defined by a longitudinally rearward portion of the first passive electrode and a longitudinally forward portion of a second ion permeable membrane, the second chamber being in communication with a hydrogen longitudinally extending passage and the first chamber being in communication with an oxygen longitudinally extending passage; c) the housing having longitudinal, vertical and lateral axes, a rearward longitudinal location and a forward longitudinal location; d) a cathode positioned in the rearward longitudinal location; e) an anode positioned in the forward longitudinal location with a plurality of first and second chambers, membranes and first passive electrodes positioned between the cathode and the anode, the plurality of first and second chambers being filled with an electrolyte solution; f) whereby gas is formed on the rearward and forward longitudinal portions of the first passive electrodes, whereby hydrogen gas is formed on the rearward portion of the first passive electrode which is passed through the hydrogen longitudinally extending passage and oxygen gas is formed upon the forward portion of the first passive electrode which passes through the oxygen longitudinally extending passage and the first and second chambers are not in gaseous communication with one another; and g) a selectively active second electrode electrically and fluidly interposed between the anode and the cathode; h) a first resistance mode wherein the second electrode is in electrical communication with either the anode or the cathode wherein electrical current only passes through a limited number of the plurality of cells; and i) a second resistance mode wherein the selectively active second electrode is not in electrical communication with either the anode nor the cathode wherein electrical current passes through all of the plurality of cells when voltage is applied to the cathode and the anode regardless of voltage applied to the selectively active second conductor.
 11. A hydrogen gas producing unit adapted to produce hydrogen from water and having longitudinal, vertical and lateral axes, the hydrogen gas producing unit comprising: a) a hydrogen gas producing portion comprising a plurality of gas production cells, the gas production cells comprising first and second chambers having lower and upper portions wherein the lower and upper portions are open one to the other such that gas flow between the lower portion and the upper portion is substantially unhindered, the first and second chambers being separated from one another for each gas production cell in part by a passive electrode and by an ion permeable membrane, the first and second chambers having a width dimension in the direction of the lateral axis greater than the height dimension in the direction of the vertical axis direction; b) wherein the lower portions are filled with fluid; c) wherein the upper portions are substantially devoid of fluid; d) an electrolyte re-circulatory channel positioned in communication with the first and second chambers, the first chamber of the plurality of cells having an upper portion in communication with a first passage, and the second chamber being in communication with a second passage; e) a fluid replenishment system comprising a fluid compartment having a fluid height sensor measuring the level of fluid therein, the fluid height sensor and the fluid compartment being in fluid communication with the first and second chambers of the plurality of cells so as to maintain the level of fluid above the lower portion of the gas producing cells; f) the gas exiting from the first chamber being hydrogen gas and being deposited through a fluid trap and extracted through a gas extractor; g) the fluid height sensor and the fluid compartment maintain the level of fluid below the point at which the gas exits the first chamber; h) a cathode and anode operatively arranged to have the passive electrodes of the plurality of cells electrically engaged between the anode and cathode; and, i) a power control system providing direct current to be passed between the anode and cathode.
 12. The electrolyzer as recited in claim 11 further comprising: a) an alternative power control system comprising: i a second selectively active conductor interposed between the anode and cathode; ii wherein at a first electrical resistance level the second selectively active conductor is in electrical communication with the anode or the cathode so electrical current only passes through a limited number of the plurality of cells; and ii wherein at a second electrical resistance level, the second selectively active conductor is not in electrical communication with the anode nor the cathode so electrical current passes through all of the plurality of cells.
 13. The electrolyzer as recited in claim 11 where electrolyzer recirculatory passages are positioned beneath the first and second chambers.
 14. The electrolyzer as recited in claim 11 wherein the first and second frame portions having a lower first and second longitudinally extending conduit adapted to pass electrolyte fluid therethrough, where a surface defining an opening defines the first and second electrolyte re-circulatory paths.
 15. The electrolyzer as recited in claim 14 where the cross-sectional area of the electrolyte supply path is less than 5% of the cross-sectional area of the first chamber in the longitudinal direction.
 16. The electrolyzer as recited in claim 14 where a surface of each of the cells creates a manifold structure for distributing electrolyte fluid through each of the first and second chambers where the fluid travels in a lateral direction.
 17. An electrolyzer comprising: a plurality of cells, each cell having: a) an oxygen subchamber and a hydrogen subchamber separated by interposed sections of a passive electrode and a membrane; b) the membrane being comprised of a hydrophobic material and the electrode and membrane cooperating to form, in part, the hydrogen and oxygen subchambers; c) a fluid entry manifold in communication with the hydrogen and oxygen subchambers by way of a fluid entry channel which transfers fluid into the oxygen and hydrogen subchambers; d) an oxygen gas trap channel provided in the cell laterally adjacent the membrane and provided to remove oxygen from the oxygen subchamber; e) the oxygen gas trap channel comprising an entry point vertically above the membrane, a first leg extending downward from the entry point to a lower point comprising an oxygen sub line in fluid communication with oxygen gas traps of adjacent cells and the gas trap channel extending upward to an oxygen passageway in fluid communication with adjacent oxygen gas traps; f) a hydrogen gas trap channel provided in the cell laterally adjacent the membrane and in communication with hydrogen subchamber; g) the hydrogen gas trap channel comprising an entry point vertically above the membrane, a first leg extending downward from the entry point to a lower point comprising a hydrogen sub line in fluid communication with hydrogen gas traps of adjacent cells and the gas trap channel extending upward to a hydrogen passageway in fluid communication with adjacent oxygen gas traps; and the electrolyzer having first and second electrode members positioned in a manner so the passive electrodes are between the current flow of the first and second electrode members and the passive electrodes are configured to produce hydrogen and oxygen on opposing sides thereof for production of hydrogen in the hydrogen subchamber and oxygen in the oxygen subchamber.
 18. The electrolyzer as recited in claim 17 where each hydrogen and oxygen subchamber is subdivided into a plurality of hydrogen subsections and oxygen subsections.
 19. The electrolyzer as recited in claim 17 where a control system has a float to add additional water into the unit.
 20. The electrolyzer as recited in claim 17 where the fluid manifold passes to an end region and travels longitudinally back towards a control system where it is circulated to an external heat exchanger. 